Space frame kinetic front transition connections

Abstract

A transition connection for a space frame can comprise a connection pad defining a first end of the transition connection, a node defining a second end of the transition connection opposite the first end, a pair of ribs on opposite sides, a first concave portion on a first side of one of the ribs, and a second concave portion on a second side of the one of ribs. In a side elevational view of the transition connection, an acute angle is formed on a same side as the first and second concave portions. The transition connection, which can be a casting, can be part of a pair or set of transition connections separate and distinct from each other. The pair of transition connections can be mirror images of each other.

The invention claimed is: 
     
       1. A space frame for an off-highway rear haul truck comprising:
 a pair of first front transition castings spaced from each other in a width direction of the space frame; 
 a pair of second front transition castings spaced from each other in the width direction of the space frame, 
 wherein each of the first front transition castings is coreless and includes:
 a connection pad on a first end of the first front transition casting and configured to weldably attach to a bottom surface of a front upper frame connection of the space frame, and 
 a node on a second end of the first front transition casting opposite the first end and configured to weldably attach to a first frame tube, 
 
 wherein each of the second front transition castings is coreless and includes:
 a connection pad on a first end of the second front transition casting and configured to weldably attach to a rear mounting surface of a front lower suspension connection of the space frame, and 
 a node on a second end of the second front transition casting opposite the first end and configured to weldably attach to a second frame tube, 
 
 wherein coreless means that each of the first front transition castings and each the second front transition castings is free of any hollow portions at any of the nodes and the connection pads, 
 wherein the pair of first front transition castings are at a first height in the space frame higher than a second height of the pair of second front transition castings, 
 wherein, for each of the first front transition castings, in a side elevational view thereof, a connection face of the connection pad is at a first acute angle relative to a face of the node, and 
 wherein, for each of the second front transition castings, in a side elevational view thereof, a connection face of the connection pad is at a second acute angle relative to a face of the node, the second acute angle being different from the first acute angle of the first front transition castings. 
 
     
     
       2. The space frame according to  claim 1 , wherein the pair of second front transition castings are mirrored relative to each other in the width direction of the space frame. 
     
     
       3. The space frame according to  claim 1 , wherein the first acute angle is less than the second acute angle. 
     
     
       4. The space frame according to  claim 1 , wherein each of the first front transition castings further includes:
 a pair of opposing ribs on opposite sides of the first front transition casting, 
 another rib between the pair of opposing ribs, 
 a first concave portion between said another rib and a first one of the ribs of the pair of opposing ribs, 
 a second concave portion between said another rib and a second one of the ribs of the pair of opposing ribs, and 
 an arcuate portion opposite the first and second concave portions. 
 
     
     
       5. The space frame according to  claim 1 , wherein each of the second front transition castings further includes:
 a pair of first opposing ribs on opposite sides of the second front transition casting, 
 a pair of second opposing ribs on opposite sides of the second front transition casting, 
 a pair of first concave portions between the pair of first opposing ribs, separated by a first one of the second opposing ribs, and 
 a pair of second concave portions between the pair of first opposing ribs, separated by a second one of the second opposing ribs. 
 
     
     
       6. The space frame according to  claim 5 , wherein the first one of the second opposing ribs is shorter than the second one of the second opposing ribs. 
     
     
       7. The space frame according to  claim 1 , wherein for each connection pad of the first and second front transition castings a perimeter thereof is chamfered. 
     
     
       8. A set of transition connections for a space frame comprising:
 a first transition connection; and 
 a second transition connection separate and distinct from the first transition connection, 
 wherein each of the first and second transition connections includes:
 a connection pad defining a first end, 
 a node defining a second end opposite the first end, 
 a pair of ribs on opposite sides, 
 a first concave portion on a first side of one of the ribs, 
 a second concave portion on a second side of said one of ribs, 
 
 wherein, for each of the first and second transition connections, in a side elevational view, an acute angle is formed on a same side as the first and second concave portions, and 
 wherein the first and second concave portions are of a same configuration. 
 
     
     
       9. The set of transition connections according to  claim 8 ,
 wherein the first and second transition connections are castings, 
 wherein the connection pad is square in an end view thereof, and 
 wherein the node is circular in an end view thereof. 
 
     
     
       10. The set of transition connections according to  claim 8 , wherein the first transition connection and the second transition connection are mirror images of each other when facing each other. 
     
     
       11. The set of transition connections according to  claim 8 , wherein each of the first and second transition connections includes an arcuate portion opposite the first and second concave portions. 
     
     
       12. The set of transition connections according to  claim 8 , wherein each of the first and second transition connections includes:
 another pair of ribs on opposite sides, 
 a third concave portion on a first side of one of the ribs of said another pair, and 
 a fourth concave portion on a second side of said one of the ribs of said another pair. 
 
     
     
       13. The set of transition connections according to  claim 12 , wherein a first one of the ribs of said another pair of ribs is shorter than a second one of the ribs of said another pair of ribs. 
     
     
       14. The set of transition connections according to  claim 8 , wherein a perimeter of each of the connection pads is chamfered. 
     
     
       15. A method comprising:
 providing a first one-piece transition casting of a set of transition castings; and 
 providing a second one-piece transition casting of the set of transition castings, the second one-piece transition casting being separate and distinct from the first one-piece transition casting, 
 wherein each of the first and second one-piece transition castings includes:
 a connection pad at a first end, 
 a node at a second end opposite the first end, 
 a pair of opposing ribs between the connection pad and the node, 
 a first concave portion on a first side of a first one of the opposing ribs, and 
 a second concave portion on a second side of said one of the opposing ribs, 
 
 wherein, for each of the first and second one-piece transition castings, in a side elevational view, an acute angle is formed on a same side as the first and second concave portions, and 
 wherein each of the first and second one-piece transition castings is coreless, meaning that each of the first and second one-piece transition castings is free of any hollow portions at the node and the connection pad. 
 
     
     
       16. The method according to  claim 15 , further comprising:
 welding, using an automated welding machine, the nodes of the first and second one-piece transition castings to respective elongate support members; and 
 welding the connection pads of the first and second one-piece transition castings to respective portions of either a bottom surface of a front upper frame connection of a space frame or a rear mounting surface of a front lower suspension connection of the space frame. 
 
     
     
       17. The method according to  claim 16 , wherein, in the side elevational view, the opposing ribs are aligned with the respective elongate support members. 
     
     
       18. The method according to  claim 16 , wherein the first and second one-piece transition castings are at a same height in the space frame. 
     
     
       19. The method according to  claim 15 , wherein, in the side elevational view, the opposing ribs are at the acute angle relative to a flat connection surface of the connection pad. 
     
     
       20. The method according to  claim 15 , further comprising:
 providing a first one-piece transition casting of another set of transition castings; and 
 providing a second one-piece transition casting of said another set of transition castings, 
 wherein the first and second one-piece transition castings of said another set of transition castings are different in terms of configuration from the first and second one-piece transition castings of said set of transition castings.